CONCEALED CEILING PANEL SYSTEM

SYSTEME DE PANNEAUX DE PLAFOND DISSIMULES

English Abstract

The present invention comprises a flexible ceiling panel preferably formed from sheet metal, such as aluminum sheet. Each ceiling panel has a generally rectangular shape (corresponding in width to the spacing between the main runners) and is formed with a hem on all four edges. A series of bendable tabs are formed integrally with the hem of the panel. To secure the panel to the associated grid system, the tabs are folded upwardly and outwardly from the panel along two axes to secure the panel to the grid system. Alternatively, a plurality of separate spring clips is used to secure the panel to the grid system. Each clip includes a first leg adapted to have at least a portion thereof received in the hem of the ceiling panel. A second leg extends generally perpendicularly from the first leg and includes a detent extending toward the first leg, the detent being adapted to secure the clip to the flange of the runner.

French Abstract

La présente invention comprend un panneau de plafond flexible formé de préférence à partir de tôles, par exemple en aluminium. Chaque panneau de plafond a généralement une forme rectangulaire (correspondant en largeur à l'espacement entre les principaux rails d'ossature) et est formé d'un rebord sur les quatre bords. Une série de pattes pliantes est formée intégralement avec le rebord du panneau. Pour fixer le panneau au système de grille associé, les pattes sont pliées vers le haut et vers l'extérieur du panneau le long de deux axes pour fixer le panneau au système de grille. Il est également possible d'utiliser plusieurs pinces de ressort séparées pour fixer le panneau au système de grille. Chaque patte d'attache inclut un premier montant adapté pour qu'au moins une partie soit accueillie par le rebord du panneau de plafond. Un second montant s'étend généralement perpendiculaire au premier montant et inclut une encoche s'étendant vers le premier montant, l'encoche étant adaptée pour fixer la patte d'attache du rail d'ossature.

Claims

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WHAT IS CLAIMED IS:
1. A ceiling panel for use in a suspended ceiling system having a support grid
comprising
a plurality of runners having flanges thereon adapted to support ceiling
panels, the ceiling panel
comprising a sheet of metal having a perimeter with a plurality of edges, each
of the edges of
being folded back onto the panel to form a hem extending substantially about
the perimeter of
the panel, the hem having a plurality of spaced-apart tabs formed integrally
therewith, each tab
having first and second portions, the first portion being secured to the hem
and adapted to be
bent about a first axis and the second portion being secured only to the first
portion, and adapted
to be bent about a second axis oriented generally obliquely to the first axis,
whereby bending
the tab about the first axis permits the first portion of the tab to lie in a
first plane generally
perpendicular to the ceiling panel and bending the tab about the second axis
permits the second
portion of the tab to lie in a second plane at an angle with respect to the
first plane to permit the
second portion of the tab to cooperate with the flange of one of the runners
to secure the ceiling
panel thereto.
2. The ceiling panel of claim 1 wherein the tab is configured to predispose it
to bending
about the first and second axes.
3. The ceiling panel of claim 2 wherein the tab includes a first aperture
lying along the first
axis and a second aperture lying along the second axis.

Description

CA 02606754 2009-09-01
CONCEALED CEILING PANEL SYSTEM
FIELD AND BACKGROUND
[0001] The present invention relates to a suspended ceiling system and, more
particularly,
a ceiling panel adapted for use in a curved suspended ceiling system in which
the suspension
grid is substantially concealed from view by the ceiling panels and in which
the panels can be
shipped in a flat configuration. In one aspect of the invention, the ceiling
panel includes tabs
formed integrally therewith for attaching the ceiling panel to the suspension
grid. In second
aspect, a clip is provided for securing the ceiling panel to a suspension
grid.
[0002] Curved suspended ceiling systems are becoming increasingly popular.
This
application discloses a unique curved suspension grid system in which the main
runners are
secured to a plurality of primary carriers that are oriented transversely to
the main runners and
extend substantially the width of the suspended ceiling.

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[ 0003lAs shown in the referenced application, the ceiling panels are
supported
directly on the top surfaces of the flanges of the main runners, as is typical
in many
suspended ceiling systems, and are secured in place by hold-down clips that
are
placed over the reinforcing bulb of the runner. However, it is sometimes
desirable,
usually for aesthetic reasons, to disguise or hide the supporting grid system
for the
panels. While this has been done for flat ceiling grids, the problems of
creating a
curved ceiling panel system that substantially conceals the support grid
system have
not been adequately addressed before the present invention.
SUMMARY OF THE INIVENTION
[ 0004]The present invention comprises a novel flexible ceiling panel
preferably
formed from sheet metal, such as aluminum sheet. Each ceiling panel has a
generally
rectangular shape (corresponding in width to the spacing between the main
runners)
and is formed with a hem on all four edges.
[ 0 0 0 5 ] Two different approaches for securing the panels to the grid
system are
contemplated. In a first embodiment of the present invention, a series of
bendable
tabs are formed integrally with the hem of the panel. To secure the panel to
the
associated grid system, the tabs are folded upwardly and outwardly from the
panel
along two axes to secure the panel to the grid system.

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0 ] In a second embodiment, a plurality of separate spring clips is used to
secure
the panel to the grid system. Each clip includes a first leg adapted to have
at least a
portion thereof received in the hem of the ceiling panel. A second leg extends
generally perpendicularly from the first leg and includes a detent extending
toward the
first leg, the detent being adapted to secure the clip to the flange of the
runner. In one
embodiment of the clip, the detent is adapted to engage an edge of the flange
of the
runner. In a second embodiment, the detent is adapted to engage an upper
surface of
the flange of the runner.
[0007 ] In a further aspect of the clip, the clip may include an angled
segment
extending from the second leg having a free end that is adapted to engage the
flange
of the runner during installation of the ceiling panel into the support grid.
BRIEF DESCRIPTION OF THE DRAWINGS
[ 0 0 0 8 ] Fig. 1 is a plan view of a ceiling panel according to a first
embodiment of the
present invention.
[ 0 0 0 9 ] Fig. 2 is a fragmentary view of the ceiling panel of Fig. 1,
enlarged to show
detail.
[00010]Figs. 3 and 4 are fragmentary perspective views illustrating the
process for
securing the ceiling panel of Fig. 1 to a grid member or runner.

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[00011]Fig. 5 is a cross-sectional view taken along line 5-5 in Fig. 4 showing
the
ceiling panel of Fig. 1 secured to a grid member.
[00012]Figs. 6, 8 and 10 illustrate a clip for securing a hemmed ceiling panel
to a grid
member, with Fig. 6 being a perspective view showing the relationship between
the
clip, the ceiling panel and the grid member, Fig. 8 being a cross-sectional
view taken
along line 8-8 of Fig. 6, and Fig. 10 being a perspective view of the clip.
[ 0 0 013 ] Figs. 7, 9 and 11 illustrate a variation of the clip of Figs. 6, 8
and 10 for
securing a hemmed ceiling panel to a grid member.
[00014]Fig. 12 is a perspective view of a tool designed to assist in removal
of a ceiling
panel secured to a grid member by the clip of Figs. 7, 9 and 11.
DETAILED DESCRIPTION
[00015 ] With reference to the accompanying drawings, the basic construction
of a
flexible ceiling panel 10 in accordance with the present invention is shown.
Specifically, the panel 10 is made from sheet metal, and preferably from
aluminum
sheet of an aluminum alloy such as 3003 H-14 or 3105 aluminum alloy. The panel
10
is typically 24 inches in width to match a standard grid module. However, a 30-
inch
width is also possible. The panel 10 may be perforated to improve acoustical
performance. Additionally, acoustical materials (such as non-woven matt and

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insulation pads, rolls or batts) can be added to the back side of the panel 10
to
improve sound absorption and reduce sound transmission.
[ 000161The panel 10 has an edge perimeter comprising a hem 12 formed by
folding
the edges of the panel 10 back on themselves on all four sides. A preferred
width for
the hem is .472 inches, although other widths may be selected without
departing from
the invention. The panel hem design allows for the panel to curve to adapt to
the
profile of the suspension grid. The panels can conform to varying convex
and/or
concave contours in a single panel, with lengths up to 12 feet being
contemplated,
depending upon handling limitations.
[ 0001 7 1 With reference to Figs. 1-5, a plurality of tabs 14 are formed
integrally with
the hem 12 spaced at intervals about the perimeter of the panel. As
illustrated, the
tabs 14 are generally rectangular in shape and have an overall dimension of 1
1/2
inches by 11/16 inches, although other shapes and dimensions may be used. Each
tab 14 is bendable relative to the hem 12 along a first axis to an angle of
approximately
900 with respect to the panel 10. A minor portion 14a (measuring approximately
1/2
inch by 11/16 inch) of each tab 14 is bendable along a second axis at an
obtuse angle
with respect to the major portion 14b of the tab 14 to provide the portion of
the tab that
engages the flange 17a of the runner 17. The tab 14 is provided with slots or
cutouts

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16 along the first and second axes that facilitate bending of the tab as
described above, although
other techniques for predisposing the clip to bend at the desired locations
may be used, such as
pre-creasing the tab 14 along the first and second axes.
[00018] The panels 10 are shipped with the tabs 14 unbent, as shown in, e.g.,
Figs. 1-3.
with reference to Figs. 4 and 5, the panels 10 are secured to a grid member or
runner 17 by first
partially bending the tabs 14 along the first axis to help guide the panel 10
into the grid opening
from below. Then, after the panel 10 is in position in the grid opening, the
tabs 14 are bent
along the second axis so that the minor portion 14a thereafter engages the
back side of the
horizontal flange 17A of the runner 17.
[00019] With reference to Figs. 6-11, a second system for securing the ceiling
panel 10
to the grid system is shown. In this system, a hemmed sheet metal panel 10 is
also provided.
However, instead of having tabs being formed integrally therewith, the hems 12
include pre-
punched holes 22 (best seen in Figs. 6 and 7) at spaced intervals that
cooperate with a clip,
generally designated 24, to locate and appropriately space the clips and to
secure the clips to the
panel.
[00020] The clip 24 is generally L-shaped, with a first or lower leg 26 having
a tab 28
being bent upwardly therefrom that is of a size and shape so that it can be
received in

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the pre-punched hole 22 in the hem 12. A second, longer leg 30 of the clip
includes a spring
tongue or detent 32 that extends generally toward the first leg 26 of the
clip. With reference
to Figs. 6, 8 and 10, the free end 33 of the detent 32 extends toward the edge
of the panel 10,
when the clip 24 is installed thereon, with an intermediate portion of the
detent 32 being curved
or bowed so as to overlie the flange 17a of the runner 17. During installation
of the panel into
the grid, the curved portion of the detent 32 pulls the panel 10 upwards and
holds the panel hem
12 against the face of the grid. The clip 24 also includes an upper angled
portion 34 that allows
the panel be initially installed below the face of the grid, with the free end
36 of the angled
portion resting on the flange of the runner, thus allowing the panels 10 to be
installed without
the clip 24 interfering with the reinforcing bulb of the runners in the grid.
[00021] The panels secured to a grid by means of the clip 24 of Figs. 6, 8 and
10 can be
removed or demounted without a special tool by simply pulling downward at the
edge of the
panel and inserting a screw driver or bladed tool at the edge. By prying
downwardly, the detent
32 can be disengaged from the flange of the runner and the panel lowered so
that the free end
of the upper angled portion 34 of the clip 24 rests on the flange of the
runners.
Final demounting of the panels is then accomplished by

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bending the vertical leg 30 by applying forger pressure to provide clearance
between the angled
portion 34 of the clip 24 and the flange 17a of the runner 17.
[00022] Alternatively, and as illustrated in Figs. 7, 9 and 11, the spring
tongue or detent
32 may be shortened so that it extends over the inner edge of the hem. When
the panel is
installed, using this clip, the free end 33 of the detent 32 engages the upper
surface of the flange
17a of the support runner 17. As such, the spring clip 24 locks the panel in
place, clamping the
flange 17a of the grid between the detent 32 and the ceiling panel 10.
Consequently, a special
tool is required to remove a panel utilizing this clip embodiment, such as the
tool 40 shown in
Fig. 12. The tool 40 has a working end 42 that is inserted between the hem of
the panel and
the bottom of the flange of the runner and then slid along the edge thereof to
disengage the
detent 32 from the top of the flange.
[00023] Thus, a system has been provided for securing a ceiling panel to a
grid system
in a manner that conceals the grid system from view. While the inventions
disclosed in the
present application are intended to be used with a curved suspension grid,
they may also be used
with a standard flat suspension grid without departing from the invention.

Representative Drawing